mortarless masonry_symposium_2010-03-30
TRANSCRIPT
![Page 1: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/1.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
“Design and Construction ofMortarless Interlocking Masonry”
Prepared by:
Jesse Edwards, Mina Gayed, Michael Pyra, & Tisbeth Rodriguez
![Page 2: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/2.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Goals Part I
– Introduction: what is mortarless masonry?– Why was it introduced and what are its
benefits?– Currently available systems– Design example
Part II– Construction aspects
• Applications and limitations
– Productivity and cost comparisons– Case study
![Page 3: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/3.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Introduction: What is mortarless masonry?
Eliminates the use of mortar in head and bed joints
Geometric interlocking mechanisms
Reinforced and grouted Post-tensioned and surface
bonded Manufactured with tighter
tolerances for alignment
![Page 4: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/4.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Current Systems AvailableName of System (Country, Year)
Block Type (Material)
Interlocking Mechanism
Reinforcement Type
Haener (USA, 1975) Hollow (concrete)
Nibs in bed joint, T&G in head joint
Vertical & horizontal
Sparlock (Canada, 1986)
Hollow (concrete)
Geometric interlocking and
stackingVertical
Mecano (Peru, 1998) Hollow (concrete) No interlocking* Vertical &
horizontal
Sparfil (Canada, 1989)
Hollow (light- weight
concrete)No interlocking* None
Whelan-Hatzinikolas-Drexel
(USA, 1992)Hollow
(concrete)Rounded dovetail lug on head joint Vertical
Azar (Canada, 1997*)
Hollow (concrete)
3 mechanisms: web key, head and bed
joint face shell interlocking
Vertical & horizontal
Silblock (India, 1999) Solid (concrete) Geometric
interlocking Vertical
![Page 5: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/5.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Masonry Statistics
60% of traditional masonry construction is skilled labour
Average age of a skilled mason in the U.S.A. and Canada is 56 years old. (National Concrete Masonry
Association)
– Influx of young skilled masons in industry is decreasing
Traditional crew consists of 3 masons and 1 labourer; the crew is reversed for mortarless masonry
Ex: Construction of house foundation– 3 unskilled labourers can construct a 1,200 block foundation in
4-5 hours Up to 10X faster than traditional masonry and cast in place concrete!
![Page 6: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/6.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Some Benefits
Significant labour savings Contractors win owners win Multitude of applications: commercial,
industrial, and residential projects All weather construction Fuels masonry growth in
the building sector Establish masonry as
a competitive material!!
![Page 7: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/7.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Design Aspects Given a shear wall:
– 200 mm block, fully grouted– 3.2 m long and 10.0 m high– Dead load: 300 kN– Shear: 200 kN & moment of 1200 kN-m
Given a flexure wall:– 200 mm block, fully grouted– 4.0 m high– Dead load: 150 kN/m– Live load: 100 kN/m
Design with 30 MPa blocks for both the traditional and Azar systems using vertical reinforcement of 15M bars @ 400 c/c
![Page 8: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/8.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Design AspectsShear Wall Flexure Wall (per meter)
Traditional Mortarless Traditional Mortarless
Axial Resistance (kN) 3348 4315 1047 1348
Moment Strength (kN-m) 1660 1680 19.5 22.3
Shear Reinforcement Yes (15M at 600mm c/c) No N/A N/A
Diagonal Shear (kN) 270 480 N/A N/A
Sliding Shear (kN) 542 542 115 115
Mortarless masonry is equal to or exceeds traditional masonry strength!
Note: Mortarless values are based on Azar Block design.
![Page 9: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/9.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
PART II - Construction
![Page 10: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/10.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
“Traditional” Applications
The North American market: – Haener: individual consumer use (primarily
Los Angeles), variable commercial applications
– Sparlock: firewall construction– Azar: house foundations and firewall
construction The untapped potential of these systems is
huge Large industrial and commercial applications
of these systems have only become more common in the last decade
![Page 11: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/11.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Integrated Systems
Integrated Masonry Systems Inc. (IMSI): cavities for insulation and electrical wires
Durisol and Faswall: Portland cement and mineralized wood fibre for high R-value and ease of handling
Primarily residential applications
IMSI
Faswall
![Page 12: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/12.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Limitations
Regional building code restrictions– Ex: Azar Block review by the Canadian
Construction Materials Center (CCMC) for compliance with NBCC:
• Buildings up to 3 storeys and an area of 600 m²• Wall construction must be fully grouted• Basement walls cannot exceed 2.5 m in height• Exterior above-grade walls and interior load-
bearing walls are limited to 20 times the wall thickness
Challenges posed by high initial settlement and attaining plumb
![Page 13: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/13.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Productivity and Cost Comparison
Two identical commercial buildings in Edmonton, AB; one built traditionally and the other with the Azar system: – 15 m (W) x 50 m (L) x 4 m (H)– 200 mm x 200 mm x 400 mm units– 20M vertical bars at 600 mm spacing– Grouted every third core (Azar fully grouted)– Traditional team: 3M-1L (30 blocks/hr)– Azar team: 1M-3L (300 blocks/hr)
![Page 14: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/14.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Productivity and Cost Comparison
Time = 1377 hrs (34.4 wks) Time = 505 hrs (12.6 wks)
$141,174
$212,511
$888
MaterialLabourEquipment
$189,360
$76,073
$2,536
MaterialLabourEquipment
$141,174
$189,360 TraditionalAzar $212,511
$76,073
TraditionalAzar
Material Comparison Labour Comparison
Traditional Construction = $354,573 Azar Mortarless System = $267,969
![Page 15: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/15.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
2,952 sq. ft. residence
Built in 2006 FlexLock Wall
System Post-tensioned walls
Case Study: Magnolia, Texas
![Page 16: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/16.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas
Laying the First Two Courses
Dry-Stacking the Walls
![Page 17: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/17.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas
Pouring the Bond Beam Tensioning the Wall
![Page 18: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/18.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas FlexLock performed a comparative cost
analysis based on installed cost of standard 8" masonry in the region:– Total masonry costs declined by 24%– Productivity increased by 120%.
![Page 19: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/19.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Condos in Bois-Franc Community, Montreal
Constructed using the Sparlock Interlocking Building System
Mortarless Construction in Canada
![Page 20: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/20.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Besser Proneq machine shop in Quebec City
Sparlock blocks use for the building envelope
Mortarless Construction in Canada
![Page 21: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/21.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Conclusion
The structural capacity of mortarless blocks is comparable to standard concrete masonry units
Not suitable for all applications Mortarless construction is more efficient and
cost-effective than conventional masonry Mortarless units are becoming more readily
available and have been implemented in many projects around the world
![Page 22: Mortarless Masonry_Symposium_2010-03-30](https://reader036.vdocuments.site/reader036/viewer/2022070601/58891dd61a28ab77528b48e1/html5/thumbnails/22.jpg)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Questions?
Sacsahuaman, Peru -1423 A.D.
“ Arguably, the biggest change in the world of concrete masonry units is the mortarless system.”
(Masonry Magazine)